Forged Aluminum Components for Lightweight Structures
Aluminum forgings have emerged as a superior alternative to both forged steel and cast aluminum components in the pursuit of vehicle weight reduction. This choice not only leads to significant productivity enhancements in high-volume production but also ensures competitive pricing.
In the realm of automotive chassis design, the use of lightweight, non-elastic materials is crucial for enhancing safety and comfort. Dr. Heinz Lowak, an engineering expert, emphasizes the advantages of aluminum forgings, stating, "Our aluminum forgings weigh only half as much as comparable steel components, offering a decisive edge." Meinertzhagen, head of sales and marketing at Otto Fuchs, highlights that aluminum forgings can achieve excellent mechanical properties, surpassing those of commonly used cast aluminum alloys. With a tensile strength of up to 440N/mm2 and a yield limit exceeding 380N/mm2, aluminum forgings exhibit superior performance in critical chassis components like lateral guides for front axles.
High Strength and Toughness:
Although castings have traditionally dominated aluminum component production due to economic reasons, recent technological advancements have enhanced the material properties of castings. Jurgen Krummel, head of Audi's "Axis Parts Development" department, acknowledges the historical limitations of forgings, such as cost constraints, which have hindered designers' flexibility. However, forged aluminum components remain prevalent in chassis applications due to their reliability and product liability considerations. Aluminum forgings offer exceptional strength, deformability, and toughness, aligning with design requirements for chassis components like lateral guides, wheel supports, thrust rods, and bearing frames.
Mass Production at Competitive Prices:
Dr. Lowak notes that advancements in manufacturing processes have made aluminum forgings economically viable for mass production. Traditionally confined to aerospace applications, aluminum forgings are now more accessible to automotive manufacturers. Recent developments have significantly reduced production costs while maintaining high reliability levels, aligning aluminum forging processes with those of steel forgings in terms of productivity. This cost optimization allows aluminum forgings to be competitively priced in the automotive industry.
Materials, Processing Technology, and Design Coordination:
Through meticulous research and development, aluminum forgings have achieved remarkable strength improvements. Dr. Lowak emphasizes the importance of in-house alloy smelting and precise control over the forging process to optimize material properties. Advanced techniques, such as directional fiber alignment and simulated forging processes, contribute to a 25% increase in static strength. However, Dr. Lowak underscores the need for collaboration between aluminum forging experts and designers to maximize results. Complex geometries and large parts may present manufacturing challenges, but stringent quality control measures ensure reliable part processing.
In conclusion, forged aluminum offers compelling solutions for lightweight structures in automotive applications. While certain limitations exist, continual process improvement and quality assurance initiatives drive advancements in aluminum forging technology, ensuring its continued relevance and adoption in the automotive industry.